U.S. patent number 10,328,523 [Application Number 14/794,538] was granted by the patent office on 2019-06-25 for fluted additive manufacturing deposition head design.
This patent grant is currently assigned to Rolls-Royce Corporation. The grantee listed for this patent is Rolls-Royce Corporation. Invention is credited to Pavlo Earle, Johnny D. Grubbs, Brandon David Ribic, Quinlan Yee Shuck.
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United States Patent |
10,328,523 |
Earle , et al. |
June 25, 2019 |
Fluted additive manufacturing deposition head design
Abstract
A material deposition head may include a body that defines first
and second ends, an exterior surface, an interior surface, and one
or more material delivery channels, where the exterior surface
includes fluting. In some examples, a system may include a fluted
material deposition head, a fluidized powder source, and an energy
source.
Inventors: |
Earle; Pavlo (Carmel, IN),
Ribic; Brandon David (Carmel, IN), Shuck; Quinlan Yee
(Indianapolis, IN), Grubbs; Johnny D. (Clayton, IN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Rolls-Royce Corporation |
Indianapolis |
IN |
US |
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Assignee: |
Rolls-Royce Corporation
(Indianapolis, IN)
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Family
ID: |
53757981 |
Appl.
No.: |
14/794,538 |
Filed: |
July 8, 2015 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20160008887 A1 |
Jan 14, 2016 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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62023442 |
Jul 11, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B33Y
30/00 (20141201); B23K 26/34 (20130101); B23K
26/144 (20151001); B28B 13/022 (20130101); B29C
64/153 (20170801); B28B 1/001 (20130101); B23K
26/1476 (20130101); Y02P 10/25 (20151101); B22F
2003/1056 (20130101); B29K 2105/251 (20130101) |
Current International
Class: |
B22F
3/105 (20060101); B23K 26/14 (20140101); B28B
1/00 (20060101); B28B 13/02 (20060101); B33Y
30/00 (20150101); B23K 26/34 (20140101); B23K
26/144 (20140101); B29C 64/153 (20170101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2329935 |
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Jun 2011 |
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EP |
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2502729 |
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Sep 2012 |
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EP |
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WO-2013137289 |
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Sep 2013 |
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WO |
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Other References
Extended Search Report from counterpart European Application No.
15176170.7, dated Nov. 9, 2015, 8 pp. cited by applicant .
Examination Report from counterpart European Application No.
15176170.7, dated May 23, 2018, 6 pp. cited by applicant .
Response to Examination Report dated May 23, 2018, from counterpart
European Application No. 15176170.7, filed Sep. 18, 2018, 34 pp.
cited by applicant.
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Primary Examiner: Malekzadeh; Seyed Masoud
Attorney, Agent or Firm: Shumaker & Sieffert, P.A.
Parent Case Text
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application
No. 62/023,442, titled, "FLUTED ADDITIVE MANUFACTURING DEPOSITION
HEAD DESIGN," filed Jul. 11, 2014, the entire content of which is
incorporated herein by reference.
Claims
The invention claimed is:
1. A material deposition head comprising: a body defining a first
end and a second end, wherein the body further defines: an exterior
surface, at least a portion of the exterior surface of the material
deposition head extending from the first end of the body to the
second end of the body; an interior surface defining an internal
passage extending from the first end to the second end; and a
material delivery channel extending from proximate to the first end
of the body to proximate to the second end of the body, wherein the
material delivery channel is configured to permit passage of a
fluidized powder therethrough, wherein the at least portion of the
exterior surface includes fluting configured to increase a surface
area of the exterior surface of the body and increase
convection-driven cooling of the material deposition head, wherein
the fluting of the exterior surface comprises a plurality of peaks
connected by a plurality of troughs, wherein the plurality of peaks
are oriented in a direction substantially orthogonal to a major
axis of the body that extends from the first end to the second end,
and wherein at least some troughs of the plurality of troughs of
the at least a portion of the exterior surface of the body form a
curve in axial cross-section with each end of the curve terminating
at a point of a peak of the plurality of peaks or at an edge of a
planar surface of the peak.
2. The material deposition head of claim 1, wherein the material
deposition head is configured to be coupled to an energy
source.
3. The material deposition head of claim 1, wherein the interior
surface of the body comprises fluting comprising a plurality of
peaks connected by a plurality of troughs, and wherein at least a
portion of the fluting of the interior surface is oriented in a
direction that forms an acute angle with a major axis of the body
that extends from the first end to the second end.
4. The material deposition head of claim 1, wherein the exterior
surface includes a chamfer that tapers radially inwardly toward the
internal passage proximate to the second end of the body, wherein a
surface of the chamfer comprises fluting comprising a plurality of
peaks connected by a plurality of troughs, and wherein the fluting
of the chamfer is oriented in a direction that forms an acute angle
with a major axis of the body that extends from the first end to
the second end.
5. The material deposition head of claim 1, wherein the material
delivery channel comprises a plurality of material delivery
channels.
6. The material deposition head of claim 1, wherein the body is
substantially cylindrical and substantially annular in a radial
cross-section, a circumference of the interior surface being less
than a circumference of the exterior surface.
7. The material deposition head of claim 1, wherein the body
comprises a first body portion, and the material deposition head
further comprises a second body portion defining a first end and a
second end, the second end of the second body portion being
configured to be coupled to the first end of the first body
portion, wherein the portion of the exterior surface comprises a
first portion, and wherein the second body portion further defines:
at least a second portion of an exterior surface of the material
deposition head extending from the first end of the second body
portion to the second end of the second body portion; an interior
surface of the second body portion defining an internal passage
extending from the first end to the second end, wherein the
internal passage of the second body portion is substantially
aligned with the internal passage of the first body portion; and a
material delivery channel for the second body portion extending
from proximate to the first end of the second body portion to
proximate to the second end of the second body portion, wherein the
material delivery channel of the second body portion is fluidically
coupled to the material delivery channel of the first body portion,
and wherein the second portion of the exterior surface includes
fluting.
8. The material deposition head of claim 7, wherein the fluting of
the exterior surface of the second portion comprises a plurality of
peaks connected by a plurality of troughs, wherein the plurality of
peaks are oriented in a direction substantially orthogonal to a
major axis of the second body portion that extends from the first
end to the second end of the second body portion.
9. The material deposition head of claim 7, wherein the interior
surface of the second body portion comprises fluting comprising a
plurality of peaks connected by a plurality of troughs, and wherein
at least a portion of the fluting of the interior surface of the
second body is oriented in a direction substantially parallel to a
major axis of the second body portion that extends from the first
end to the second end of the second body portion.
10. The material deposition head of claim 7, wherein the material
delivery channel of the first body portion comprises a plurality of
material delivery channels, and the material delivery channel of
the second body portion comprises a plurality of material delivery
channels, wherein each respective material delivery channel of the
plurality of material delivery channels of the first body portion
is fluidically coupled to at least one material delivery channel of
the plurality of material delivery channels of the second body
portion.
11. The material deposition head of claim 7, wherein the second
body portion is substantially cylindrical and substantially annular
in a radial cross-section, a circumference of the interior surface
being less than a circumference of the exterior surface of the
second body portion.
12. A system comprising: a material deposition head comprising a
body defining a first end and a second end, wherein the body
further defines: an exterior surface, at least a portion of an
exterior surface of the material deposition head extending from the
first end of the body to the second end of the body; an interior
surface defining an internal passage extending from the first end
to the second end, wherein the internal passage is configured to
permit passage of an energy beam therethrough; a material delivery
channel extending from proximate to the first end of the body to
proximate to the second end of the body, wherein the material
delivery channel is configured to permit passage of a fluidized
powder therethrough, wherein the at least a portion of the exterior
surface includes fluting configured to increase a surface area of
the exterior surface of the body and increase convection-driven
cooling of the material deposition head, wherein the fluting of the
exterior surface comprises a plurality of peaks connected by a
plurality of troughs, wherein the plurality of peaks are oriented
in a direction substantially orthogonal to a major axis of the body
that extends from the first end to the second end, and wherein at
least some troughs of the plurality of troughs of the at least a
portion of the exterior surface of the body form a curve in axial
cross-section with each end of the curve terminating at a point of
a peak of the plurality of peaks or at an edge of a planar surface
of the peak; a fluidized powder source coupled to the material
delivery channel; and an energy source coupled to the internal
passage.
13. The system of claim 12, wherein the material deposition head
comprises a laser material deposition head, the fluidized powder
comprises at least one of metal, alloy, ceramic, or polymeric
particles carried by a fluid, the energy source comprises a laser,
and the energy beam comprises a laser beam generated by the
laser.
14. The system of claim 12, wherein the interior surface of the
body comprises fluting comprising a plurality of peaks connected by
a plurality of troughs, wherein at least a portion of the fluting
of the interior surface is oriented in a direction that forms an
acute angle with a major axis of the body that extends from the
first end to the second end.
15. The system of claim 12, wherein the exterior surface includes a
chamfer that tapers radially inwardly toward the internal passage
proximate to the second end of the body.
16. The system of claim 15, wherein a surface of the chamfer
comprises fluting comprising a plurality of peaks connected by a
plurality of troughs, wherein the fluting of the chamfer is
oriented in a direction that forms an acute angle with a major axis
of the body that extends from the first end to the second end.
17. The system of claim 12, wherein the body comprises a first body
portion, and the material deposition head further comprises a
second body portion defining a first end and a second end, the
second end of the second body portion being configured to be
coupled to the first end of the first body portion, wherein the
portion of the exterior surface comprises a first portion, and
wherein the second body portion further defines: at least a second
portion of an exterior surface of the material deposition head
extending from the first end of the second body portion to the
second end of the second body portion; an interior surface of the
second body portion defining an internal passage extending from the
first end to the second end, wherein the internal passage of the
second body portion is substantially aligned with the internal
passage of the first body portion; and a material delivery channel
for the second body portion extending from proximate to the first
end of the second body portion to proximate to the second end of
the second body portion, wherein the material delivery channel of
the second body portion is fluidically coupled to the material
delivery channel of the first body portion, wherein the second
portion of the exterior surface includes fluting.
18. The system of claim 17, further comprising: a tube configured
to be coupled to the material delivery channel defined by the
second body portion proximate to the first end of the second body
portion, wherein the tube is configured to transport fluidized
powder from the fluidized powder source; a nozzle configured to be
coupled to the second end of the first body portion, wherein the
nozzle is fluidically coupled to the material delivery channel of
the first body portion and configured to deliver the fluidized
powder adjacent to a substrate.
Description
TECHNICAL FIELD
The present disclosure describes a head for use in additive
manufacturing.
BACKGROUND
Additive manufacturing generates three-dimensional structures
through addition of material layer-by-layer or volume-by-volume to
form the structures, rather than removing material from an existing
component to generate three-dimensional structures. Additive
manufacturing may be advantageous in certain circumstances, such as
rapid prototyping, forming components with complex
three-dimensional structures, or the like. In some examples, the
additive manufacturing process may utilize a laser to melt or
sinter together powdered materials in predetermined shapes to form
the three-dimensional structures.
SUMMARY
The present disclosure describes a material deposition head used in
the additive manufacturing process that includes fluting on one or
more of its surfaces, to facilitate convection-driven cooling of
and reduced absorption of heat by the head. The material deposition
head may be coupled to an energy source, such as a laser. A fluid
source, such as an inert gas, may carry a material through one or
more internal channels of the material deposition head, which
directs the material to be deposited on a substrate, to be heated
by an energy source coupled to the material deposition head. For
example, a laser may be positioned to deliver a laser beam through
an open, inner portion of a laser material deposition head to
deliver energy to and heat metal or alloy particles directed by a
nozzle of the head on a substrate in a predetermined pattern. A gas
that carries the metal or alloy particles through the material
delivery channel of the laser material deposition head may deflect
from the substrate back toward the head and pass over fluting
positioned on one or more exterior surfaces of the head. Fluting
may be oriented in particular directions, for example, to increase
the surface area of contact between a gas and the fluting, reduce
absorption of heat radiating from an energy source associated with
the additive manufacturing process, or direct gas flowing over the
fluting in a particular direction. Including fluting on one or more
surfaces of a material deposition head may allow for higher
operating temperatures or power to be used in the additive
manufacturing process than otherwise would be possible without a
fluted head design.
In some examples, a material deposition head of this disclosure may
include a body that defines a first end and a second end, an
exterior surface extending from the first end of the body to the
second end of the body, and an interior surface that defines an
internal passage extending from the first end to the second end.
The body of the material deposition head also may define a material
delivery channel extending from proximate to the first end of the
body to proximate to the second end of the body, where the exterior
surface of the body includes fluting.
In addition, in some examples, a material deposition head may be a
laser material deposition head, and fluting may be disposed (e.g.,
by machining) on an exterior and/or interior surface of the body of
the laser material deposition head. Such fluting may include a
plurality of peaks connected by a plurality of troughs. An exterior
surface of the body of a material deposition head of this
disclosure also may include, in some examples, a chamfer that
tapers inwardly toward the internal passage of the body, where the
chamfer also including fluting. Additionally or alternatively, the
material delivery channel of the body may include a plurality of
material delivery channels, and the body may include multiple
portions, for example, a first body portion and a second body
portion that are configured to be coupled together.
In some examples, a system of this disclosure may include a
material deposition head that has a body defining a first end and a
second end, where the body further defines an exterior surface that
extends from the first end of the body to the second end of the
body, and an interior surface defining an internal passage that
extends from the first end to the second end. Such an internal
passage may be configured to permit passage of an energy beam
therethrough. The material delivery channel defined by the body
extends from proximate to the first end of the body to proximate to
the second end of the body, wherein the material delivery channel
is configured to permit passage of a fluidized powder therethrough,
wherein the exterior surface of the body includes fluting. Such an
exemplary system also may include a fluidized powder source coupled
to the material delivery channel, and an energy source coupled to
the internal passage.
The details of one or more examples are set forth in the
accompanying drawings and the description below. Other features,
objects, and advantages will be apparent from the description and
drawings, and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an exploded perspective view of an exemplary material
deposition head described by this disclosure.
FIG. 2 is an exploded alternative view of the exemplary material
deposition head of FIG. 1.
FIG. 3 is a block diagram of an exemplary system including a
material deposition head, among other features, as described by
this disclosure.
DETAILED DESCRIPTION
The present disclosure describes material deposition heads used in
additive manufacturing (e.g., material addition or
three-dimensional fabrication) that have fluting defined on one or
more surfaces of the heads to at least one of facilitate cooling of
the heads, reduce the absorption of heat, or enhance performance of
the heads during the additive manufacturing process. During
additive manufacturing, a component is built by adding material to
the component in sequential layers. The final component is composed
of a plurality of layers of material. In some additive
manufacturing techniques for forming components from metals,
alloys, polymers, or ceramics, a powder may be delivered to a
surface of a previously formed layer using a carrier gas, and an
energy source may be directed at predetermined volumes of the
powder to heat the powder and join the powder to the previously
formed layer. The heating of the powder may, in some examples,
cause the powder to sinter or melt to join the powder to the
previously formed layer and/or a substrate material. The heat
source may be, for example, a laser. The heat source and the
sintering or melting may generate heat, at least some of which may
be absorbed by the material deposition head. Left unchecked, this
heating may affect operation of the material deposition head, e.g.,
by damaging the material deposition head.
In some examples, the material deposition head may be fluted along
one or more exterior surfaces to increase convection-driven cooling
of the material deposition head compared to a deposition head with
no fluting, other process parameters being equal. Sources of heat
that may be absorbed by the material deposition head during the
additive manufacturing process may include, for example, heat from
an energy beam (e.g., a laser) passing through a focal passage in
the interior of the head, or heat radiating from a melt pool of
material at which the laser is directed. During the additive
manufacturing process, a gas carrying powdered material through a
material delivery channel and out a nozzle coupled to the material
deposition head may impact the substrate to which the additive
manufacturing process is adding material, then deflect back toward
the material deposition head. In such an example, the gas may pass
over fluting on one or more exterior surfaces of the material
deposition head. Fluting a surface of the material deposition head
increases the total surface area of the material deposition head
and may increase convection-driven cooling compared to a material
deposition head without fluting on its exterior surface(s). In some
examples, the fluted material deposition heads of this disclosure
may exhibit an operating temperature that is about 40.degree. C.
lower than material deposition heads not including fluting, when
compared under the same deposition parameters.
In some examples, the material deposition head also may be fluted
along one or more interior surfaces, such as the focal passage for
the energy source. For example, an inner circumference of an
interior surface of the material deposition head may define a
center focal passage through which an energy source, such as a
laser, may be focused (e.g., focused adjacent to the surface to
which material is to be added). The interior surface of the
material deposition head that defines the center focal passage may
be fluted.
Material deposition heads including fluting on an external surface,
an internal surface, or both, may facilitate cooling of the
material deposition heads without utilizing a liquid cooling
medium, such as water. In some examples, water cooling of material
deposition heads may be undesirable or impracticable. For example,
when the size or volume of a material deposition head is small,
when there is limited access to smaller components of a material
deposition head, when additive manufacturing is carried out in a
sealed or inert environment, and/or when reduction of the risk of
water contamination is desired, water cooling of a material
deposition head may be problematic. The material deposition heads
described herein may reduce the risk of liquid contamination or
leakage during an additive manufacturing process, may allow for a
reduced footprint of the material deposition head compared to
material deposition heads cooled by liquids, or both.
FIG. 1 is an exploded perspective view of an exemplary material
deposition head 2 according to this disclosure. In the example
illustrated in FIG. 1, material deposition head 2 includes a first
body portion 4 and a second body portion 48. In other examples,
material deposition head 2 may include a single body portion or
more than two body portions. First body portion 4 of material
deposition head 2 defines a first end 6a and a second end 6b at
opposing ends of first body portion 4, and an exterior surface 10
of body 4 extending from first end 6a to second end 6b. First body
portion 4 defines a major axis 22 extending from first end 6a to
second end 6b. In some examples, at least a portion of one or both
of first end 6a and second end 6b includes a planar surface.
As shown in FIG. 1, first body portion 4 also may define an
interior surface 12 that defines an internal passage 14 within
first body portion 4. Internal passage 14 may extend from first end
6a to second end 6b of first body portion 4 and be configured to
permit passage therethrough of an energy beam generated by an
energy source. For example, an energy beam generated by an energy
source may pass through internal passage 14 of first body portion
4, exit material deposition head 2 at second end 6b along major
axis 22 (for example, in line with line 91 shown in FIG. 1), impact
a material disposed on or adjacent to the substrate by a fluidized
powder directed adjacent to the substrate, and be absorbed by the
material. In some examples, as shown in FIG. 1, first body portion
4 may be substantially cylindrical in shape (for example,
cylindrical or nearly cylindrical), such that exterior surface 10
defines an outer circumference of first body portion 4, and
interior surface 12 defines an inner circumference of first body
portion 4. In some such examples, first body portion 4 may be
substantially annular in a radial cross-section (for example,
annular or nearly annular), and the circumference of interior
surface 12 is less than the circumference of exterior surface 10.
The radial cross-section of first body portion 4 may be in a plane
substantially orthogonal to major axis 22. First body portion 4 of
material deposition head 2 may be composed of any suitable
material, for example, a metal, such as aluminum or copper, an
alloy, such as an aluminum alloy or a copper alloy, a ceramic, or
the like. Such a material or materials may, in some examples,
exhibit relatively little wear from a fluidized powder that passes
therethrough.
First body portion 4 of material deposition head 2 also may define
one or more material delivery channels 16 that extend from first
end 6a, or from proximate to first end 6a, to second end 6b, or to
proximate to second end 6b of first body portion 4. For example
first, body portion 4 may define a plurality of material delivery
channels 16, such as four material deliver channels 16.
In some examples, at least a portion of each channel of a plurality
of material delivery channels 16 may form a separate channel then
converge with other material delivery channels 16 proximate to
second end 6b, in the form of a manifold or a single channel. In
other examples, some or all of each channel of the plurality of
delivery channels 16 may not converge proximate to second end 6b,
with each channel being fluidically coupled to a respective nozzle,
such as four material delivery channels 16 fluidically coupled to
four respective nozzles. Material delivery channels 16 are
configured to provide a path for delivery of the material to be
deposited by material deposition head 2 in carrying out the
additive manufacturing process. For example material deposition
heads including multiple material delivery channels 16, the
channels may distribute a substantially equal volume (e.g., an
equal volume or nearly equal volume) of a material, such as a
fluidized powder, from a material source through each of the
multiple channels. In some examples, the material may be provided
and flow through material delivery channels 16 as a fluidized
powder, in which a flowing fluid carries powder of the material
through material delivery channels 16. In some examples, the fluid
includes a gas, such as, for example, a source of helium, argon, or
other substantially inert gas. As used herein, a substantially
inert gas may include a gas that does not react with a substrate or
the material being added to the substrate during the additive
manufacturing process.
At or proximate to second end 6b of first body portion 4 of
material deposition head 2, material delivery channels 16 may be
fluidically coupled to a nozzle 20, or each material delivery
channel may be fluidically coupled to its own respective nozzle (as
shown in FIG. 2). For example, each material delivery channel of
the plurality of material delivery channels 16 may be coupled to a
respective nozzle 20 using an insert 18, which may be, for example,
cylindrical in shape, with an inner circumference defining an
opening and an outer circumference defining an exterior surface, as
shown in FIG. 1. A first end 19a of insert 18 (e.g., a tube or
helical insert) may engage with an aperture defined in second end
6b of first body portion 4 of material deposition head 2, while a
second end 19b of insert 18 may be coupled to, engage with, or
receive nozzle 20. In other examples, nozzles 20 may be attached
directly to first body portion 4 of material deposition head 2,
without a respective insert 18.
Nozzle 20 includes a channel 21 that may be fluidly coupled to one
or more material delivery channels 16 of first body portion 4.
Material carried by a fluid, such as a fluidized powder, may be
expelled via channel 21 of nozzle 20 and directed adjacent to a
surface of a substrate to be added to the surface of the substrate
during the additive manufacturing process.
In some examples, first body portion 4 includes fluting 24 on
exterior surface 10. As discussed above, fluting 24 may increase
the surface area of exterior surface 10 of body 4, as compared to
an exterior surface without fluting, e.g., a smooth exterior
surface. Fluting 24 of exterior surface 10 of body 4 may include a
plurality of peaks 26 connected by a plurality of troughs 28, as
shown in FIG. 1. Each peak of the plurality of peaks 26 may have a
width that remains constant or varies as the peak traverses
exterior surface 10, and may include a planar surface in some
examples. Each trough of the plurality of troughs 28 likewise may
have a width that remains constant or varies as the trough
traverses exterior surface 10. Each peak and each trough, as
described, may have a same width or a different width as compared
to adjacent peaks and troughs. Thus, the pitch (distance) between
adjacent peaks may be constant or may vary. Moreover, the height of
each peak, measured with respect to the depth of an adjacent
trough, may be constant or may vary, as compared to adjacent
peaks.
Fluting 24 also may include, in some examples, a series of grooves
in exterior surface 10. In some examples, at least some (or all) of
the troughs of the plurality of troughs 28 of exterior surface 10
of body 4 may form a curve in axial cross-section (e.g., when
fluting 24 is oriented in a direction orthogonal to major axis 22),
such as a u-shaped curve, with each end of the curve terminating at
a point of a peak of the plurality of peaks 26 or at an edge of a
planar surface of a peak. In other examples, the plurality of peaks
26 and plurality of troughs 28 may form a continuous curve in axial
cross-section (again, when fluting 24 is oriented in a direction
orthogonal to major axis 22), such as a sinusoidal curve, as they
traverse exterior surface 10. Fluting 24 may be continuous or
discontinuous in any direction (e.g., the radial or axial
direction).
Additionally or alternatively, fluting 24 may be oriented in a
direction substantially orthogonal (e.g., orthogonal or nearly
orthogonal) to a major axis 22 of body 4 that extends from first
end 6a to second end 6b. Orienting fluting 24 in a direction
substantially orthogonal to major axis 22 of body 4 also may place
fluting 24 in a direction substantially orthogonal to the direction
of flow of fluids (such as a gas) that may impact a substrate at
which the material deposition head 2 is directed then deflect back
toward the head 2. In other examples, fluting 24 may be oriented in
other directions, for example, oriented substantially parallel
(e.g., parallel or nearly parallel) to major axis 22, or oriented
at some angle between orthogonal and parallel to major axis 22.
Fluting 24 (or any other fluting on material deposition head 2, in
general) also may allow for increased dissipation of heat (e g ,
infrared energy) absorbed by body 4 or material deposition head 2
from heat sources associated with additive manufacturing, such as
an energy source (e.g., a laser) or a melt pool of material being
deposited. Fluting, as described by this disclosure, may be formed
on first body 4 or material deposition head 2 by any suitable
method, for example, by machining, material ablation, or the like.
In some examples, fluting in a particular direction may be applied
based, among other reasons, on ease of forming the fluting in a
particular direction by use of machining.
In some examples, exterior surface 10 may include a chamfer 32
that, for example, tapers radially inwardly toward internal passage
14 proximate to second end 6b of body 4, as shown in FIG. 1. A
surface of chamfer 32 also may include fluting 34. In some
examples, fluting 34 may include a plurality of peaks 36 connected
by a plurality of troughs 38. In some examples, at least some (or
all) of the troughs of the plurality of troughs 38 of chamfer 32
may form a curve in radial cross-section (e.g., when fluting 34 is
oriented in a direction that forms an acute angle with major axis
22), such as a u-shaped curve, with each end of the curve
terminating at a point of a peak of the plurality of peaks 36 or at
an edge of a planar surface of a peak. In other examples, the
plurality of peaks 36 and plurality of troughs 38 on chamfer 32 may
form a continuous curve in radial cross-section (again, when
fluting 34 is oriented in a direction forming an acute angle with
major axis 22), such as a sinusoidal curve, as they traverse
exterior surface 10. Fluting 34 may be oriented in a direction that
forms an acute angle with major axis 22, by virtue of placement of
fluting 34 on the radially inwardly tapering chamfer 32, as shown
in FIG. 1. In other examples, fluting 34 may be oriented in other
directions, for example, at some angle between orthogonal and
parallel to major axis 22.
Further, each peak of the plurality of peaks 36 may have a width
that remains constant or varies as the peak traverses chamfer 32,
and may include a planar surface in some examples. For example, the
planar surface of each peak of plurality of peaks 36 of chamfer 32
may narrow in width as the peak approaches second end 6b of body 4.
Fluting 34 also may include, in some examples, a series of grooves
on chamfer 32. Fluting 34 may be continuous or discontinuous in any
direction (e.g., the radial or axial direction). Each trough of the
plurality of troughs 38 likewise may have a width that remains
constant or varies as the trough traverses the chamfer 32. Each
peak and each trough on chamfer 32 may have a same width or a
different width as compared to adjacent peaks and troughs. Thus,
the pitch (distance) between adjacent peaks may be constant or
vary. Moreover, the height of each peak, measured with respect to
the depth of an adjacent trough, may be constant or vary, as
compared to adjacent peaks.
Placement of fluting 34 on chamfer 32 in an orientation that forms
an acute angle with major axis 22 may reduce absorption of heat (e
g , infrared energy) from a melt pool of material at which an
energy source coupled to the material deposition head is related,
increase convection driven cooling of material deposition head 2
due to its increased surface area, and direct gas deflected from
the substrate toward fluting 24 to facilitate convection driven
cooling of material deposition head 2. To the extent energy from an
energy source (e.g., a laser) coupled to material deposition head 2
may radiate or reflect from a substrate back toward material
deposition head 2 or chamfer 32, orientation of fluting 34 on
chamfer 32 in a direction that forms an acute angle with major axis
22 also may reduce absorption of energy or heat radiated or
reflected from this source.
In some examples, interior surface 12 also may include fluting 40.
Fluting 40 may include a plurality of peaks 42 connected by a
plurality of troughs 44. In some examples, at least some (or all)
of the troughs of the plurality of troughs 44 of interior surface
12 of body 4 may form a curve in radial cross-section (e.g., when
fluting 40 is oriented in a direction parallel to major axis 22),
such as a u-shaped curve, with each end of the curve terminating at
a point of a peak of the plurality of peaks 42 or at an edge of a
planar surface of a peak. In other examples, the plurality of peaks
42 and plurality of troughs 44 may form a continuous curve in
radial cross-section, such as a sinusoidal curve, as they traverse
interior surface 12. Fluting 40 may be continuous or discontinuous
in any direction (e.g., the radial or axial direction).
In some examples, fluting 40 may be oriented in a direction that is
substantially parallel to major axis 22 (for example, parallel or
nearly parallel). In other examples, fluting 40 may be oriented in
a direction that forms an acute angle with major axis 22, as shown
in FIG. 1. In still other examples, fluting 40 may be oriented in a
direction substantially orthogonal to major axis 22, or in any
angle between orthogonal and parallel to major axis 22. Each peak
of the plurality of peaks 42 may have a width that remains constant
or varies as the peak traverses interior surface 12, and may
include a planar surface 46 in some examples. For example, planar
surface 46 of each peak of plurality of peaks 42 may narrow in
width as the peak approaches second end 6b of body 4. Each trough
of the plurality of troughs 44 likewise may have width that remains
constant or varies as the trough traverses interior surface 12.
Each peak and each trough, as described, may have a same width or a
different width as compared to adjacent peaks and troughs. Thus,
the pitch (distance) between adjacent peaks may be constant or
vary. Moreover, the height of each peak of the plurality of peaks
42, measured with respect to the depth of an adjacent trough, may
be constant or vary, as compared to adjacent peaks. Fluting 40 also
may include, in some examples, a series of grooves in interior
surface 12.
In some examples, an inner circumference of first body portion 4
defined by interior surface 12 may decrease, and internal passage
14 of first body portion 4 may narrow, when measured in a direction
moving from first end 6a toward second end 6b. In other examples,
an inner circumference of first body portion 4 defined by interior
surface 12 may stay substantially constant (e.g., constant or
nearly constant), when measured in a direction moving from first
end 6a toward second end 6b.
In some examples, a gas also may be purged through internal passage
14 of first body portion 4, flowing from first end 6a to second end
6b of first body portion 4. The gas may be sourced from, for
example, a gas source coupled to material deposition head 2 coupled
to material deposition head 2. In examples that include a narrowing
inner circumference of first body portion 4, the velocity of the
gas flowing through internal passage 14 may increase as the gas
flows from first end 6a to second end 6b, increasing cooling or
heat transfer along interior fluting and/or exterior fluting when
the gas deflects from the substrate back toward material deposition
head 2 including exterior fluting. A gas passing through internal
passage 14 with an increased velocity also may provide improved
protection to optics components (e.g., an energy source, such as a
laser) from splatter (e.g., metal splatter from the melt pool of
material deposited on a substrate). A narrowing internal passage 14
also may prevent clipping of a converging energy beam (e.g., a
laser beam) that passes through internal passage 14. In some
examples, a narrowing internal passage 14 may create additional
space at second end 6b of first body portion 4 for placement of
additional components, such as for one or more nozzles coupled to
second end 6b of first body portion 4. Further, placement of
fluting 40 on interior surface 12 in an orientation that forms an
acute angle with major axis 22 may reduce absorption of heat from a
melt pool of material at which an energy source coupled to the
material deposition head is related, increase convection driven
cooling of material deposition head 2 due to its increased surface
area, and direct gas deflected from the substrate toward fluting 24
for additional convection-driven cooling of the head.
As illustrated in FIG. 1, in some examples, material deposition
head 2 may include a first body portion 4 configured to be coupled
to a second body portion 48. Second body portion 48 may define a
first end 50a and a second end 50b at opposing ends of second body
portion 48. In some examples, at least a portion of one or both of
first end 50a and second end 50b includes a planar surface. Second
body portion 48 also defines major axis 22 extending from first end
50a to second end 50b. In such an example, first body portion 4 and
second body portion 48 may be coupled by any suitable means, such
as by one or more of a plurality of screws 52 that pass through at
least part of first body portion 4 and at least part of second body
portion 48, as shown in FIG. 1. For example, first end 6a of first
body portion 4 may be coupled to second end 50b of second body
portion 48 by a plurality of screws 52 disposed in respective
threaded holes of a plurality of threaded holes in first body
portion 4 and second body portion 48 that are aligned. First body
portion 4 or second body portion 48 also may include holes,
threaded holes, or any other suitable means that allows either of
first body portion 4 or second body portion 48 to be attached to
the other portion or to other components associated with the
additive manufacturing system. In general, material deposition head
2, or certain portions thereof, may include machined regions that
enable components of the head 2 to be mechanically fastened
together, or the head 2 to be mechanically fastened to other
components used in the additive manufacturing system.
As shown in FIG. 1, second body portion 48 may include an exterior
surface 54 that extends from first end 50a to second end 50b.
Second body portion 48 also may define an interior surface 56 that
defines an internal passage 58 within second body portion 48.
Internal passage 58 may extend from first end 50a to second end 50b
of second body portion 48. When first body portion 4 and second
body portion 48 are assembled, internal passage 58 of second body
portion 48 may be substantially aligned (e.g., aligned or nearly
aligned) with internal passage 14 of first body portion 4, such
that the internal passages together may be configured to allow
passage of an energy beam therethrough during the additive
manufacturing process. In some examples, as shown in FIG. 1, second
body portion 48 may be substantially cylindrical in shape (e.g.,
cylindrical or nearly cylindrical), such that exterior surface 54
defines an outer circumference of second body portion 48, and
interior surface 56 defines an inner circumference of second body
portion 48. In some such examples, second body portion 48 may be
substantially annular in a radial cross-section (e.g., annular or
nearly annular), and the circumference of interior surface 56 is
less than the circumference of exterior surface 54. The radial
cross-section of second body portion 48 may be in a plane
substantially orthogonal to major axis 22. Second body portion 48
of material deposition head 2 may be composed of any suitable
material, for example, a metal, such as aluminum or copper, an
alloy, such as an aluminum alloy or copper alloy, a ceramic, or the
like.
Second body portion 48 of material deposition head 2 also may
define one or more material delivery channels (not shown in FIG. 1)
that extend from first end 50a, or from proximate to first end 50a,
to second end 50b, or to proximate to second end 50b of second body
portion 48. For example, second body portion 48 may define a
plurality of material delivery channels, such as four channels. In
some examples, each material delivery channel of the plurality of
material delivery channels of the second body portion 48 may be
substantially aligned (e.g., aligned or nearly aligned) with and/or
fluidically coupled to a respective material delivery channel of
material delivery channels 16 of first body portion 4, such that
the channels are configured to provide a path for delivery of the
material (e.g., a fluidized powder) to be deposited by material
deposition head 2 in carrying out the additive manufacturing
process. In other such examples, each material delivery channel of
the plurality of delivery channels 16 of first body portion 4 may
be fluidically coupled to at least one material delivery channel of
second body portion 48. For example, two material delivery channels
16 of first body portion 4 may be fluidically coupled to one
material delivery channel of second body portion 48, and two other
material delivery channels 16 of first body portion 4 may be
fluidically coupled to one other material delivery channel of
second body portion 48 of material deposition head 2. As noted, in
some example material deposition heads, first body portion 4 may
have a different number of material delivery channels 16 than
second body portion 48. For example, an introductory channel 67 (as
shown in FIG. 1) on the surface of first end 50a may be fluidically
coupled to two material delivery channels that extend from first
end 50a to second end 50b of second body portion 48. In such an
example, each delivery channel of second body portion 48 may be
fluidically coupled to a respective transitional channel 69 in the
surface of second end 50b (shown in FIG. 2), where each
transitional channel 69 is fluidically coupled to one or more
material delivery channels 16 of first body portion 4 (e.g., each
transitional channel 69 may be fluidically coupled to two material
delivery channels 16 of first body portion 4).
At or proximate to first end 50a of second body portion 48 (as
shown in FIG. 1), material delivery channels (not shown in FIG. 1)
of second body portion 48 may be coupled with tube 30, which
fluidically connects the material delivery channels to a fluidized
powder source, or in some examples, a fluid source (e.g., a gas
source) or a material source (e.g., a powder source). In some
examples, as shown in FIG. 1, tube 30 may be fluidically coupled to
the material delivery channels of second body portion 48 via
introductory channel 67. Although FIG. 1 illustrates a single tube
30 for fluidically coupling material delivery channels of second
body portion 48 to a fluidized powder source, in other examples,
material deposition head 2 may include a plurality of tubes 30 for
fluidically coupling material delivery channels of second body
portion 48 to one or more gas, material, or fluidized powder
sources. A gas, material, or fluidized powder source also may be
fluidically coupled to material deposition head 2 using a tube,
pipe, conduit, or the like, that allows fluid communication. As
described, the material the fluid carries, to be deposited in a
layer on a substrate, may include at least one of a metal, alloy
(e.g., an alloy of nickel and titanium), ceramic, or polymer. In
some examples, such as when material deposition head 2 includes a
single body portion, tube 30 may fluidically couple a fluidized
powder source to material delivery channels 16 of first body
portion 4.
In some examples, second body portion 48 includes fluting 60 on
exterior surface 54. As discussed above, fluting 60 may increase
the surface area of exterior surface 54 of second body portion 48,
as compared to an exterior surface without fluting, e.g., a smooth
exterior surface. Similar to exterior surface 10 first body portion
4, fluting 60 of exterior surface 54 of second body portion 48 may
include a plurality of peaks 62 connected by a plurality of troughs
64, as shown in FIG. 1. Each peak of the plurality of peaks 62 may
have a width that remains constant or varies as the peak traverses
exterior surface 54, and may include one ore more planar surfaces
in some examples. Each trough of the plurality of troughs 64
likewise may have a width that remains constant or varies as the
peak traverses exterior surface 54. Each peak and each trough, as
described, may have a same width or a different width as compared
to adjacent peaks and troughs. Thus, the pitch (distance) between
adjacent peaks may be constant or vary. Moreover, the height of
each peak, measured with respect to the depth of an adjacent
trough, may be constant or may vary, as compared to adjacent
peaks.
Fluting 60 also may include, in some examples, a series of grooves
in exterior surface 54. In some examples, at least some (or all) of
the troughs of the plurality of troughs 64 of exterior surface 54
of second body 48 may form a curve in axial cross-section (e.g.,
when fluting 60 is oriented in a direction orthogonal to major axis
22), such as a u-shaped curve, with each end of the curve
terminating at a point of a peak of the plurality of peaks 62 or at
an edge of a planar surface of a peak. In other examples, the
plurality of peaks 62 and plurality of troughs 64 may form a
continuous curve in axial cross-section (again, when fluting 60 is
oriented in a direction orthogonal to major axis 22), such as a
sinusoidal curve, as they traverse exterior surface 54. Fluting 60
may be continuous or discontinuous in any direction (e.g., the
radial or axial direction). For example, fluting 60 may be disposed
continuously on the entirety of exterior surface 54, or disposed
only on portions of exterior surface 54.
Additionally or alternatively, fluting 60 may be oriented in a
direction substantially orthogonal (e.g., orthogonal or nearly
orthogonal) to the major axis 22 of second body portion 48 that
extends from first end 50a to second end 50b. Orienting fluting 60
in a direction substantially orthogonal to major axis 22 of second
body portion 48 also may place fluting 60 in a direction
substantially orthogonal to the direction of flow of fluids (such
as a gas) that may impact a substrate at which the material
deposition head 2 is directed then deflect back toward the head 2.
In other examples, fluting 24 may be oriented in other directions,
for example, oriented substantially parallel (e.g., parallel or
nearly parallel) to major axis 22, or oriented at some angle
between orthogonal and parallel to major axis 22. In some examples,
fluting 60 on exterior surface 54 of second body portion 48 may be
oriented in a different direction than fluting 24 on exterior
surface 10 of first body portion 4. In other examples, fluting 60
and fluting 24 are oriented in the same direction with respect to
major axis 22. Fluting 60 may allow for increased dissipation of
heat (e.g., infrared energy) absorbed by second body portion 4 or
material deposition head 2 from heat sources associated with
additive manufacturing, such as an energy source (e.g., a laser) or
a melt pool of material being deposited.
In some examples, interior surface 56 of second body portion 48
also may include fluting 66. Fluting 66 may include a plurality of
peaks 68 connected by a plurality of troughs 70. Each peak of the
plurality of peaks 68 may have a width that remains constant or
varies as the peak traverses interior surface 56, and may include
one ore more planar surfaces 72 in some examples. For example,
planar surface 72 of each peak of plurality of peaks 68 may narrow
in width as the peak approaches second end 50b of second body
portion 48. In some examples, each trough of the plurality of
troughs 70 likewise may have a width that remains constant or
varies as the trough traverses interior surface 56. In some
examples, one or more parts of some peaks of the plurality of peaks
68 may include a curvilinear surface.
Each peak and each trough, as described, may have a same width or a
different width as compared to adjacent peaks and troughs. Thus,
the pitch (distance) between adjacent peaks may be constant or
vary. Moreover, the height of each peak, measured with respect to
the depth of an adjacent trough, may be constant or vary, as
compared to adjacent peaks.
Fluting 66 also may include, in some examples, a series of grooves
in interior surface 56. In some examples, at least some (or all) of
the troughs of the plurality of troughs 70 of interior surface 56
may form a curve in radial cross-section (e.g., when fluting 66 is
oriented in a direction parallel to major axis 22), such as a
u-shaped curve, with each end of the curve terminating at a point
of a peak of the plurality of peaks 68 or an edge of a planar
surface of a peak. In other examples, the plurality of peaks 68 and
plurality of troughs 70 may form a continuous curve in radial
cross-section, such as a sinusoidal curve, as they traverse
interior surface 56. Fluting 66 may be continuous or discontinuous
in any direction (e.g., the radial or axial direction).
In some examples, fluting 66 may be oriented in a direction that is
substantially parallel to major axis 22 (for example, parallel or
nearly parallel), as shown in FIG. 1. In other examples, fluting 66
may be oriented in a direction that is substantially orthogonal to
major axis 22. In still other examples, fluting 66 may be oriented
in a direction that forms some angle with major axis 22 between
orthogonal and parallel to major axis 22.
In some examples, an inner circumference of second body portion 48
defined by interior surface 56 may decrease, and internal passage
58 of second body portion 48 may narrow, when measured in a
direction moving toward second end 50b. For example, placement of
fluting 60 on interior surface 56 in a parallel orientation or an
orientation that forms an acute angle with major axis 22 may reduce
absorption of heat from an energy source (e.g., a laser or energy
beam), from a melt pool of material at which an energy source
coupled to material deposition head 2 is related, and increase
convection driven cooling of material deposition head 2 due to its
increased surface area.
FIG. 2 is an exploded alternative view of the example material
deposition head 2 shown in FIG. 1. FIG. 2 illustrates, for example,
two transitional channels 69, each transitional Chanel 69 being
formed in a surface of second end 50b of second body portion 48.
Each transitional channel 69 is fluidically coupled to one or more
material delivery channels of second body portion 48 (e.g., each
transitional channel 69 is fluidically coupled to one material
delivery channel of second body portion 48) and to one or more
material delivery channels 16 of first body portion 4 (e.g., each
transitional channel 69 is fluidically coupled to two material
delivery channels 16 of first body portion 4). FIG. 2 also
illustrates second end 6b of first body portion 4 including a
concave surface to which one or more nozzles 20 (e.g., four
nozzles) are coupled. In some examples, second end 6b may include a
substantially planar surface (e.g., planar or nearly planar). FIG.
2 also shows that the inner circumference of first body portion 4
defined by interior surface 12 may decrease, and internal passage
14 of first body portion 4 may narrow, when measured in a direction
moving from first end 6a toward second end 6b. As shown in FIG. 2,
a narrowing internal passage 14 may create additional space at
second end 6b for placement of additional components, such as for
one or more nozzles 20 coupled to second end 6b of first body
portion 4.
FIG. 3 is a conceptual block diagram of an example system 80
described by this disclosure, which may include a material
deposition head 2. Material deposition head 2 of system 80 may
include some or all of the various features described herein with
respect to material deposition head 2 and FIG. 1. Similar to or the
same as described with respect to exemplary material deposition
head 2 of FIG. 1, material deposition head 2 of system 80 may
include a single body or multiple bodies (e.g., first body portion
4 and second body portion 48), and may include fluting on an
external surface and, optionally, an interior surface.
The body of material deposition head 2 also may define one or more
material delivery channels 16 that extend from proximate to the
first end of the body to proximate to the second end of the body.
The one or more material delivery channels 16 of the body of
material deposition head 2 may be configured to permit passage of a
fluidized powder 86 therethrough. Fluidized powder 86 may be
supplied by a fluidized powder source 84 coupled to material
delivery channels 16 of the body of material deposition head 2 of
system 80. Fluidized powder 86 may include, for example, metal,
alloy, ceramic, or polymeric particles carried by a gas. Fluidized
powder source 84 may include, for example, a source of helium,
argon, or other substantially inert gas fluidically coupled with a
source of powder, such as metal, alloy, ceramic, or polymeric
particles. Fluidized powder source 84 may be subject to, for
example, pressure or vacuum, to enable delivery of fluidized powder
86 from fluidized powder source 84 through a tube (such as tube
30), material delivery channels 16, and a channel of a nozzle
(e.g., channel 21 of nozzle 20, as described with reference to FIG.
1).
System 80 also may include an energy source 82 coupled to (e.g.,
mechanically coupled to, or positioned in alignment with) an
internal passage 14 defined by the body of material deposition head
2. Energy source 82 may generate an energy beam 90 that passes
through internal passage 14 and heats a material 92 disposed on a
substrate 88 by the fluidized powder 86 directed at substrate 88
via nozzle 20, as shown in FIG. 3. Material 92 may include, for
example, metal, alloy, ceramic, or polymeric particles, e.g.,
metal, alloy, ceramic, or polymeric particles from fluidized powder
86. In some examples, energy source 82 may include a laser, plasma
source, plasma arc, electrical arc, ultraviolet energy source,
infrared energy source, induction coil, or another source of energy
may be coupled to (e.g., mechanically coupled to) a material
deposition head. Example laser sources include a CO laser, a
CO.sub.2 laser, a Nd:YAG laser, or the like. For example, system 80
may include a laser positioned to direct a laser beam generated by
the laser through the internal passage defined by the body of a
laser material deposition head, such that the laser beam heats
metal, alloy, ceramic, or polymeric particles directed at a
substrate as part of the additive manufacturing process. In some
examples, energy source 82 may be selected to provide energy beam
90 with a predetermined wavelength or wavelength spectrum that may
be absorbed by material 92 to be added to substrate 88 during the
additive manufacturing process. A laser may operate during the
additive manufacturing process to heat, sinter, or melt the
material being added to the substrate (or being joined to the
substrate) at temperatures in the range of 1000.degree. C. to
4000.degree. C. with respect to materials such as polymers,
including copolymers, thermoplastics, and thermosets; ceramics,
including carbides, nitrides, and oxides; metals, alloys (e.g.,
nickel-base alloys and titanium-based alloys), ferrous metallic
alloys, or non-ferrous metallic alloys. In additive manufacturing
processes that utilize lasers operating in the referenced
temperature range but do not include material deposition heads
including the fluting described by this disclosure, such deposition
heads may warm to at least 300.degree. C. during the additive
manufacturing process, which may cause distortion to components of
the head (e.g., metal components, such as aluminum alloy
components).
Nozzle 20 coupled to material deposition head 2, as described with
respect to FIGS. 1 and 2, or material deposition head 2 itself, may
be positioned at any number of angles with respect to substrate 88.
In some examples, nozzle 20 and/or material deposition head 2 may
be movable in at least one dimension (e.g., translatable and/or
rotatable) to direct fluidized powder 86, and/or energy beam 90
from energy source 82 toward a selected location adjacent to a
substrate. For example, the direction of the path of fluidized
powder 86 expelled through nozzle 20 may form an acute angle or
right angle with substrate 20. Additionally or alternatively,
substrate 88 may be movable in at least one dimension relative to
material deposition head 2 so that material deposition head 2,
and/or components thereof, interact with a selected location
adjacent to substrate 88.
In some examples, the material deposition head described herein is
an ultra small diameter material deposition head, for example, a
cylindrically shaped material deposition head that has a diameter
of less than half an inch. The material deposition head may be used
in material deposition techniques for additive manufacturing of
relatively small components or adding material to locations of
components with relatively small clearances. Because of the small
size of the material deposition head, using water cooling may not
be practical, as the water cooling components may make the material
deposition head too large to fit in the desired spaces. Thus, the
fluting provided on surfaces of the material deposition head
described herein may provide increased cooling of the material
deposition head compared to a material deposition head without
fluting, while reducing or minimizing an increase in size of the
material deposition head.
Clause 1: A material deposition head comprising: a body defining a
first end and a second end, wherein the body further defines: an
exterior surface extending from the first end of the body to the
second end of the body; an interior surface defining an internal
passage extending from the first end to the second end; and a
material delivery channel extending from proximate to the first end
of the body to proximate to the second end of the body, wherein the
exterior surface of the body includes fluting.
Clause 2: The material deposition head of clause 1, wherein the
material deposition head comprises a material deposition head
coupled to an energy source.
Clause 3: The material deposition head of clause 1 or 2, wherein
the fluting of the exterior surface of the body comprises a
plurality of peaks connected by a plurality of troughs, wherein the
plurality of peaks are oriented in a direction substantially
orthogonal to a major axis of the body that extends from the first
end to the second end.
Clause 4: The material deposition head of any one of clauses 1-3,
wherein the interior surface of the body comprises fluting
comprising a plurality of peaks connected by a plurality of
troughs, and wherein at least a portion of the fluting of the
interior surface is oriented in a direction that forms an acute
angle with a major axis of the body that extends from the first end
to the second end.
Clause 5: The material deposition head of any one of clauses 1-4,
wherein the exterior surface of the body includes a chamfer that
tapers radially inwardly toward the internal passage proximate to
the second end of the body, wherein a surface of the chamfer
comprises fluting comprising a plurality of peaks connected by a
plurality of troughs, and wherein the fluting of the chamfer is
oriented in a direction that forms an acute angle with a major axis
of the body that extends from the first end to the second end.
Clause 6: The material deposition head of any one of clauses 1-5,
wherein the material delivery channel comprises a plurality of
material delivery channels.
Clause 7: The material deposition head of any one of clauses 1-6,
wherein the body is substantially cylindrical and substantially
annular in a radial cross-section, the circumference of the
interior surface being less than the circumference of the exterior
surface.
Clause 8: The material deposition head of any one of clauses 1-7,
wherein the body comprises a first body portion, and the material
deposition head further comprises a second body portion defining a
first end and a second end, the second end of the second body
portion being configured to be coupled to the first end of the
first body portion, wherein the second body portion further
defines: an exterior surface extending from the first end of the
second body portion to the second end of the second body portion; a
interior surface defining an internal passage extending from the
first end to the second end, wherein the internal passage of the
second body portion is substantially aligned with the internal
passage of the first body portion; and a material delivery channel
extending from proximate to the first end of the second body
portion to proximate to the second end of the second body portion,
wherein the material delivery channel of the second body portion is
fluidically coupled to the material delivery channel of the first
body portion, and wherein the exterior surface of the second body
portion includes fluting.
Clause 9: The material deposition head of clause 8, wherein the
fluting of the exterior surface of the second body portion
comprises a plurality of peaks connected by a plurality of troughs,
wherein the plurality of peaks are oriented in a direction
substantially orthogonal to a major axis of the second body portion
that extends from the first end to the second end of the second
body portion.
Clause 10: The material deposition head of clause 8 or 9, wherein
the interior surface of the second body portion comprises fluting
comprising a plurality of peaks connected by a plurality of
troughs, and wherein at least a portion of the fluting of the
interior surface of the second body is oriented in a direction
substantially parallel to a major axis of the second body portion
that extends from the first end to the second end of the second
body portion.
Clause 11: The material deposition head of any one of clauses 8-10,
wherein the material delivery channel of the first body portion
comprises a plurality of material delivery channels, and the
material delivery channel of the second body portion comprises a
plurality of material delivery channels, wherein each respective
material delivery channel of the plurality of material delivery
channels of the first body portion is fluidically coupled to at
least one material delivery channel of the plurality of material
delivery channels of the second body portion.
Clause 12: The material deposition head of any one of clauses 8-11,
wherein the second body portion is substantially cylindrical and
substantially annular in a radial cross-section, the circumference
of the interior surface being less than the circumference of the
exterior surface of the second body portion.
Clause 13: A system comprising: a material deposition head
comprising a body defining a first end and a second end, wherein
the body further defines: an exterior surface extending from the
first end of the body to the second end of the body; an interior
surface defining an internal passage extending from the first end
to the second end, wherein the internal passage is configured to
permit passage of an energy beam therethrough; and a material
delivery channel extending from proximate to the first end of the
body to proximate to the second end of the body, wherein the
material delivery channel is configured to permit passage of a
fluidized powder therethrough, and wherein the exterior surface of
the body includes fluting; a fluidized powder source coupled to the
material delivery channel; and an energy source coupled to the
internal passage.
Clause 14: The system of clause 13, wherein the material deposition
head comprises a laser material deposition head, the fluidized
powder comprises at least one of metal, alloy, ceramic, or
polymeric particles carried by a fluid, the energy source comprises
a laser, and the energy beam comprises a laser beam generated by
the laser.
Clause 15: The system of clause 13 or 14, wherein the fluting of
the exterior surface of the body comprises a plurality of peaks
connected by a plurality of troughs, wherein the plurality of peaks
are oriented in a direction substantially orthogonal to a major
axis of the body that extends from the first end to the second
end.
Clause 16: The system of any one of clauses 13-15, wherein the
interior surface of the body comprises fluting comprising a
plurality of peaks connected by a plurality of troughs, wherein at
least a portion of the fluting of the interior surface is oriented
in a direction that forms an acute angle with a major axis of the
body that extends from the first end to the second end.
Clause 17: The system of any one of clauses 13-16, wherein the
exterior surface of the body includes a chamfer that tapers
radially inwardly toward the internal passage proximate to the
second end of the body.
Clause 18: The system of clause 17, wherein a surface of the
chamfer comprises fluting comprising a plurality of peaks connected
by a plurality of troughs, wherein the fluting of the chamfer is
oriented in a direction that forms an acute angle with a major axis
of the body that extends from the first end to the second end.
Clause 19: The system of any one of clauses 13-18, wherein the body
comprises a first body portion, and the material deposition head
further comprises a second body portion defining a first end and a
second end, the second end of the second body portion being
configured to be coupled to the first end of the first body
portion, wherein the second body portion further defines: an
exterior surface extending from the first end of the second body
portion to the second end of the second body portion; an interior
surface defining an internal passage extending from the first end
to the second end, wherein the internal passage of the second body
portion is substantially aligned with the internal passage of the
first body portion; and a material delivery channel extending from
proximate to the first end of the second body portion to proximate
to the second end of the second body portion, wherein the material
delivery channel of the second body portion is fluidically coupled
to the material delivery channel of the first body portion, wherein
the exterior surface of the second body portion includes
fluting.
Clause 20: The system of clause 19, further comprising: a tube
configured to be coupled to the material delivery channel defined
by the second body portion proximate to the first end of the second
body portion, wherein the tube is configured to transport fluidized
powder from the fluidized powder source; a nozzle configured to be
coupled to the second end of the first body portion, wherein the
nozzle is fluidically coupled to the material delivery channel of
the first body portion and configured to deliver the fluidized
powder adjacent to a substrate.
Various examples have been described. These and other examples are
within the scope of the following claims.
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